DESCRIPTION The D1CMD Class I Div. 1 Continuity Monitor Device provides the cable termination and explosion proof seal parts needed to make the power end electrical connections associated with Nelson Heat Tracing Systems self-regulating heater cables. KIT CONTENTS 1 CMD Enclosure 1 Stand-off 1 Tube of Silicone 1 Power Termination 1 Sealing Grommet 1 Seal Fitting 1 Sealing Compound 1 Male Adapter 1 X Fiber 2 Pipe Clamps Sealing Compound Chico CMD Enclosure Green Ground Screw Silicone X Fiber Wire Nuts Cover Gasket Enclosure Cover Male Adapter Seal Fitting Sealing Grommet Stand-off Pipe Clamps *ITEMS NOT INCLUDED IN KIT *Fiberglass Tape *Heater Cable (305mm (12") loop) Sheet 1 of 8
STAND-OFF POSITIONING Sealing Grommet 178mm (7") 254mm (10") approx. Stand-off Pipe Clamps Fiberglass Tape; not included in kit 305mm (12") loop of additional heater cable Take approximately 357mm (14 ) of the heater cable and push it through the bottom opening of the stand-off. Leaving a 305mm (12 ) loop of additional cable to be installed after the stand-off is secured. Allow 178mm (7 ) of the heater cable for termination. Mount the stand-off to pipe using the pipe clamps included in kit. Do not install pipe clamps over the heater cable. Secure the additional l305mm (12 ) loop of heater to the pipe using fiberglass tape (not included in kit). Prepare heater cable for termination. Proceed to Overjacket Stripping Procedures on sheet 3. Slide the sealing grommet over heater cable and position at stand-off. Sheet 2 of 8
OVERJACKET STRIPPING PROCEDURES DO NOT CUT BRAID 178mm (7") Lightly cut around heater overjacket 178mm (7 ) from the end. Bend cable to break overjacket. Lightly cut overjacket up the center between first cut mark and the cable end. Bend cable to break overjacket. At the bulge, separate the braid to make an opening. While bending the heater cable, work it through the braid opening. Remove overjacket from heater cable. 165mm (6.5") Move braid back toward the overjacket, creating a bulge. Pull the braid tight. Proceed to Outer Jacket Stripping Procedures on sheet 4. Sheet 3 of 8
OUTER JACKET STRIPPING PROCEDURES 76mm (3") Lightly cut around heater outer jacket 76mm (3") from the end. Bend cable to break outer jacket. Lightly cut the outer jacket up the center between the first cut mark & the cable end. Bend cable to break outer jacket. Starting at the end, pull each bus wire away from the core material. Remove exposed core material. Remove the jacket from the heater cable. Cut 6mm (0.25") off the end of each bus wire. Proceed to Power Termination on sheet 5. DO NOT CUT BUS WIRES Shave the core material from the outside of each bus wire. Sheet 4 of 8
POWER TERMINATION Bus wires must not touch or cross while inserting into power termination. Only power terminations specifically approved for the vendors style and type of heater cable must be used. apply silicone here Insert bus wires into power termination. Squeeze power termination opening and fill with silicone. Push power termination to overlap jacket. Proceed to Seal Fitting Installation on sheet 6. Sheet 5 of 8
SEAL FITTING PROCEDURES Male Adapter Seal Fitting X Fiber Note: If this kit is mounted in an orientation that would allow the sealing compound to flow out, place packing material (X Fiber) around the heater cable. Slide seal fitting over the heater cable and braid, screw onto the stand-off by hand until snug fit. Note: The heater cable must be positioned in the seal fitting so the braid transition point is visible through the seal fitting opening. See Detail A on sheet 8. Slide male adapter over the heater cable and braid, screw into seal fitting by hand until snug fit. Proceed to Sealing Compound Procedure on sheet 7. Sheet 6 of 8
CMD ENCLOSURE Place the CMD enclosure over the heater cable and braid, screw onto male adapter until secured. Connect each heater cable bus wire with each of the CMD capacitor lead wires using wire nuts. See diagram on sheet 1. Place cover gasket and cover onto the CMD enclosure; screw until tightened. Mix sealing compound according to the instructions on the pouch. Knead to mix liquid and powder in pouch. Snip off a corner of the pouch and fill the seal fitting. Sealing compound must completely cover the braid transition point. See Detail A on sheet 8 for reference. Sheet 7 of 8
TEMPLATE Ground braid seperation point (See Detail "A", below) 74mm (2.9") 29mm (1.1") 51mm (2") 13mm (.5") 165mm (6.5") Sealing Grommet Sealing Compound Heater Cable Dotted lines show minimum sealing compound levels for vertical & horizontal positioned seal. Stand-off X-Fiber (for use when seal fitting is placed in horizontal position only) Power Termination Heater Cable Outer Jacket Seal Fitting Sealing Depth min. 25mm (1.0") Ground Braid (must be separated inside seal fitting and completely covered by sealing compound) DETAIL A Nelson Heat Tracing Systems products are supplied with a limited warranty. Complete Terms and Conditions may be found on Nelson's website at www.nelsonheaters.com. Sheet 8 of 8